Method of assembling camera for vehicular applications

ABSTRACT

A method of assembling a vehicular camera includes providing front and rear housing members, a lens assembly and a circuit board. An imager is disposed on a first side of the circuit board and a connector is disposed on a second side of the circuit board. A conduit includes a plurality of electrically conductive elements terminating at (i) a first connecting end configured to electrically connect to the circuit board connector disposed on the second side of the circuit board and (ii) a second connecting end configured to electrically connect to a wire harness of a vehicle equipped with the vehicular camera and the vehicular vision system. The conduit is secured relative to the rear housing member to provide at least 110 N of strain relief in any axis with respect to the conduit. The front housing member and the rear housing member are attached.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/180,644, filed Jun. 13, 2016, now U.S. Pat. No. 9,992,392, which is acontinuation of U.S. patent application Ser. No. 14/672,699, filed Mar.30, 2015, now U.S. Pat. No. 9,365,160, which is a continuation of U.S.patent application Ser. No. 13/936,708, filed Jul. 8, 2013, now U.S.Pat. No. 8,994,878, which is a continuation of U.S. patent applicationSer. No. 12/580,496, filed Oct. 16, 2009, now U.S. Pat. No. 8,482,664,which claims the benefits of U.S. provisional application Ser. No.61/148,568, filed Jan. 30, 2009, and U.S. provisional application Ser.No. 61/105,852, filed Oct. 16, 2008.

FIELD OF THE INVENTION

The present invention relates to a camera for use in vehicles, and moreparticularly rearview cameras for use in vehicles.

BACKGROUND OF THE INVENTION

A typical camera for mounting on a vehicle has a lens member, an imagingelement, a circuit board and housing members that connect together. Itis generally desirable to reduce the cost of manufacture of such camerasand to improve their reliability.

As an example, some cameras may use an epoxy to mount the lens member tothe front housing member. However, the epoxy that is used may besusceptible to softening under high temperature, at which point the lensmember becomes vulnerable to being moved out of focus with the imagingelement. It would be desirable to reduce the vulnerability of the lensmember to movement under high temperature.

Another problem with some cameras relates to the cable that exits thecamera and extends to other vehicular components. A camera may bepositioned within a protective housing, which may be closed about thecamera or sensor and secured together. The camera includes a wireharness or wire or lead electrically connected to circuitry of thecamera and extending through the camera housing for electricalconnection to a vehicle wire harness or the like.

A need exists for an inexpensive camera cable exit strategy that isspace efficient, hermetically sealed, provides substantial of cablestrain relief in any axis (such as, for example, more than about 110 Nof cable strain relief in any axis), and can withstand the stresses ofautomotive environmental conditions. Currently used grommets in theindustry tend to leak when subjected to off axis stresses. Also, manyexisting exit strategies incorporate additional and complex contactinterfaces along the conductive paths from wire to board so that pins orspecific terminals are introduced which can be press-fit or over-moldedinto a sealed plastic interface. This may increase cost, complexity andquality risks associated with the camera cable.

It would be advantageous to provide a camera that addresses one or moreof these and other considerations.

SUMMARY OF THE INVENTION

In a first aspect, the invention is directed to a camera for mounting ona vehicle, wherein the camera housing made up of two housing members,with a conductive coating on the interior of each of the housingmembers. The two housing members mate together using an interferencefit, to provide a greater assurance that they are electrically connectedto each other. One of the housing members is connected to ground.

In a particular embodiment of the first aspect, the camera includes afront housing member, a lens member, an imaging element, a circuit boardand a rear housing member. The front housing member has a front housingmember interior surface that has a front housing member coating ofelectrically conductive material thereon. The lens member is mounted tothe front housing member. The imaging element is positioned to receiveimages from the lens member. The circuit board is configured to send toanother component signals relating to images received by the imagingelement. The rear housing member has a rear housing member interiorsurface that has a rear housing member coating thereon. The fronthousing member and the rear housing member are sized to mate togetherwith an interference fit such that the front housing member coating andthe rear housing member coating engage each other. One of the front andrear housing member coatings is electrically connectable to ground.

In a second aspect, the invention is directed to a camera for a vehicle,having a lens member that is movable to a selected position on the fronthousing member, optionally by means of engagement of a threaded portionon the lens member and a corresponding threaded portion on the fronthousing member. The lens member is holdable in the selected position byan interference fit.

In a particular embodiment of the first aspect, the camera includes afront housing member, a lens member, an imaging element and a circuitboard. The front housing member has a lens member receiving aperturetherein having a front housing member threaded portion, and a fronthousing member locking portion. The lens member is mounted to the fronthousing member. The lens member has a lens member threaded portion formating with the front housing member threaded portion, and a lens memberlocking portion. The lens member locking portion and the front housingmember locking portion are sized to mate together with an interferencefit to hold the lens member in a selected position relative to the fronthousing member. The imaging element is positioned to receive video inputfrom the lens member. The circuit board is configured to send to anothercomponent signals relating to video input received by the imagingelement.

In another aspect, the present invention provides a camera module thathas a housing and a wire harness or wire or lead that is electricallyconnected to circuitry of the camera and that extends through the camerahousing for electrical connection to a vehicle wire harness or the like.The wire or lead extends through a portion of the housing with thehousing disposed at the wire prior to connection of the wire to thecircuitry of the camera. The electrical connection of the wire to thecamera circuitry is made as the housing is assembled. The joint at wherethe wire extends outward from the housing portion is sealed, such as viashrink wrapping or the like.

According to another aspect of the present invention, a camera modulefor a vision system of a vehicle includes a circuit board, a lens holderor lens mounting assembly for mounting a lens assembly, and an outershell or housing portion. The circuit board includes a lens assembly, animaging sensor and associated circuitry. The outer shell or housingportion includes first and second housing portions, with a wire or leadextending through the first housing portion for connection to thecircuit board. The wire includes a connector at the first housingportion that is configured to connect to a connecting element at thecircuit board when the first and second housing portions are assembledtogether to encompass or house the circuit board within the outer shellor housing portion.

The outer shell or housing portion may comprise a lens receiving portionand a cable receiving portion, with the lens receiving portion and thecable receiving portion being connected together to substantially housethe circuit element within the housing portion. The cable receivingportion includes a connector receiving portion and a wire receivingportion, with the connector receiving portion being formed to receiveand retain the cable connector therein and the wire receiving portionbeing formed to receive and retain the cable portion therein.

These and other objects, advantages, purposes and features of thepresent invention will become apparent upon review of the followingspecification in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will now be described by way of example only withreference to the attached drawings, in which:

FIG. 1a is a front end view of a camera for a vehicle in accordance withan embodiment of the present invention;

FIG. 1b is a sectional view along section line 1 b-1 b shown in FIG. 1a;

FIG. 2 is a perspective view of a front housing member that is part ofthe camera shown in FIGS. 1a and 1 b;

FIG. 3 is an exploded perspective view of an imaging device inaccordance with another embodiment of the present invention;

FIG. 4 is a perspective view of the cable and rear housing portion ofthe imaging device of FIG. 3; and

FIG. 5 is a sectional view of the cable and rear housing portion of FIG.4.

DETAILED DESCRIPTION OF THE INVENTION

Reference is made to FIG. 1a , which shows a camera 30 for use in avehicle, and in particular for use as a rearview camera in a vehicle, inaccordance with an embodiment of the present invention. In one aspect,the camera 30 is configured to provide grounding protection andelectromagnetic compatibility (EMC) protection simply and without addingto the complexity of the assembly. Referring to FIG. 1b , which is asectional view of the camera 30, the camera 30 includes a lens 32, animaging element 33, a circuit board 34, a front housing member 36 and arear housing member 38.

Note that the terms ‘front’ and ‘rear’ as used in the present documentrefer to the front of the camera 30 (i.e. the portion of the camerawhere the lens member is located), and the rear of the camera 30 (i.e.the portion of the camera 30 opposite the front of the camera 30). Whenthe camera 30 is used in a rearview application in a vehicle, the frontof the camera 30 thus faces rearwardly relative to the vehicle and therear of the camera 30 faces towards the front of the vehicle.

The lens member 32 may be any suitable lens member known in the art, andis mounted to the front housing member 36. The imaging element 33 ispositioned in a selected position to receive images through the lensmember 32. The imaging element 33 may be any suitable imaging element acharge-coupled device (CCD) or a complimentary metal-oxide semiconductor(CMOS) sensor. The circuit board 34 receives signals from the imagingelement 33 and sends signals relating to images received on the imagingelement 33 to one or more other components such as another computingdevice within the vehicle. The imaging element 33 may be mounteddirectly on the circuit board 34.

The circuit board 34 may be mounted to the front housing member 36 inany suitable way. For example, the circuit board 34 may be mounted tothe front housing member 36 by a plurality of circuit board mountingfasteners 40, which may be mechanical fasteners such as machine screwsthat engage apertures 41 (e.g. threaded apertures) on the front housingmember 16. A plurality of front electrical connectors 42 are provided onthe circuit board 34.

The rear housing member 38 houses a plurality of rear electricalconnectors 44 that are electrically connected at their front ends to thefront electrical connectors 42 on the circuit board 34 and at their rearends to a plurality of electrical conduits 46, which connect the circuitboard 34 to associated elements in the vehicle.

The front electrical connectors 42 may be male electrical connectors,and the rear electrical connectors 44 may be female electricalconnectors that receive the male front electrical connectors 42 as shownin FIG. 1 b.

While a plurality of front and rear electrical connectors 42 and 44 areshown, it is alternatively possible for the camera 30 to have as few asone front electrical connector 42, one rear electrical connector 44 andone electrical conduit 46.

The front and rear housing members 36 and 38 may be made from anysuitable material, such as a polymeric material. In instances whereinthe front and rear housing members 36 and 38 may build up a staticelectrical charge it is preferable to provide means to inhibit such abuildup so as to protect components such as the circuit board 34. Toinhibit the buildup of static electricity on the front housing member36, a front housing member coating 48 of electrically conductivematerial may be provided on the front housing member interior surface,shown at 50. The aperture 41 may have the front housing member coating36 thereon so that the circuit board mounting fastener 40 is in directcontact with the front housing member coating 36. The circuit boardmounting fastener 40 may be made from an electrically conductivematerial. One of the front electrical connectors 42 may be a frontground connector 42 a, and connects to a rear ground connector 44 a,which in turn connects to a ground point within the vehicle (not shown)through one of the electrical conduits, shown at 46 a. The front groundconnector 42 a may be electrically connected to the front housing membercoating 36 any suitable way. For example, the front ground connector 42a may be electrically connected to the circuit board mounting fastener40 by an electrical trace shown at 51 on the circuit board 34 or by someother suitable electrical conduit. The front ground connector 42 athereby conducts any buildup of electricity away from the front housingmember 36 to the rear ground connector 44 a, which in turn conducts theelectricity to a ground point in the vehicle. The front housing membercoating 36 may be any suitable material, such as Aluminum.

To inhibit the buildup of static electricity on the rear housing member38, a rear housing member coating 52 of electrically conductive materialmay be provided on the rear housing member interior surface, shown at54. The rear housing member coating 52 may be electrically (andphysically) connected to the front housing member coating throughengagement between the rear housing member interior surface 54 with aplurality of engagement ribs 56 on the front housing member interiorsurface 50, which have the front housing member coating 48 thereon. Theengagement ribs 56 are more clearly shown in FIG. 2. Referring to FIG.1b , to provide a relatively greater assurance of electricalcommunication between the rear and front housing member interiorsurfaces 54 and 48, the rear housing member interior surface 54 and theengagement ribs 56 may be sized to have an interference fittherebetween.

Any electrical charge that is built up on the rear housing member 38 isconducted away by the rear housing member coating 52 to the fronthousing member coating 48, through the electrically conductive circuitboard mounting fastener 40, along the aforementioned electrical trace51, through the front and rear electrical connectors 42 a and 44 a,through the ground conduit 46 a out to ground at a suitable location inthe vehicle. While three engagement ribs 56 are shown at two opposingcorners of the front housing member 36, any suitable number of ribs 56may be provided. The engagement between the ribs 56 and the rear housingmember 38 align the rear housing member 38 with respect to the fronthousing member 36.

After the front and rear housing members 36 and 38 are mated togetherusing the engagement ribs 56, they may be further joined by means ofwelding, adhesive, or any other suitable means.

In addition to providing a means for grounding the front and rearhousing members 36 and 38, the front and rear housing member coatings 48and 52 also provide EMC protection to the circuit board 34.

After the housing members 36 and 38 are mated together they may befurther joined together by means of welding, adhesive or any othersuitable means.

Referring to FIG. 1b , the structure shown for holding the lens member32 in position relative to the front housing member 36 is shown, inaccordance with another aspect of the present invention. The camera 30is configured to hold the lens member 32 in position securely even atrelatively high temperatures, such as temperatures that exceed 85degrees Celsius.

The lens member 32 and the imaging element 33 are mounted at a selecteddistance from one another so as to focus images received by the lensmember 32 on the imaging element 33. As noted above, the imaging element33 may be mounted on the circuit board 34, which may itself be mountedat a fixed position on the front housing member 36 by any suitablemeans, such as by the plurality of circuit board mounting fasteners 40which are received in the plurality of apertures 41 in the front housingmember 36. To provide some adjustability for setting the distancebetween the lens member 32 and the imaging element 33, the lens member32 may have thereon a threaded portion 76 that is received in aninternally threaded portion 78 in the lens member receiving aperture,shown at 79, on the front housing member 36. In addition to theengagement of the threaded portions 76 and 78, a suitable bonding agent,shown at 80, such as an epoxy that is cured using ultra-violet (UV)light, may be applied between the lens member 32 and the front housingmember 36 to retain the lens member 32 in a selected position relativeto the imaging element 33. Additionally, the front housing member 36 mayinclude a front housing member locking portion 81 with a plurality oflens member engagement ribs 82 thereon that are positioned and sized toform an interference fit with a lens member locking portion 84 on thelens member 32. The lens member engagement ribs 82 are shown moreclearly in FIG. 2. In the embodiment shown in FIG. 2, three engagementribs 82 are provided. In embodiments wherein three engagement ribs 82are provided, they may be spaced about the perimeter of the lens memberreceiving aperture 79 sufficiently to hold the lens member 32 (FIG. 1b )centered with respect to the front housing member axis, shown at Afhm. Asufficient spacing for this purpose would be provided if the maximumangular spacing between any two adjacent engagement ribs 82 were lessthan 180 degrees of the lens member receiving aperture 79. In theembodiment shown, the spacing between any two adjacent engagement ribs82 is 120 degrees.

While three engagement ribs 82 are shown in FIG. 2, it is, however,possible to have fewer or more lens member engagement ribs 82. Forexample, two engagement ribs could be provided, wherein each rib extendsover an angular range instead of having an apex as shown for the ribs 82shown FIG. 2.

While the engagement ribs 82 are shown as being on the front housingmember locking portion 81, it is alternatively possible to provide themon the lens member locking portion 84.

It is optionally possible to omit the engagement ribs 82 and to simplyprovide an interference fit between two substantially cylindricallocking portions 81 and 84, however, it is contemplated that the use ofengagement ribs 82 as shown in FIGS. 1b and 2 reduces the force requiredto rotate the lens member 32 to its optimal position for focusing imageson the imaging element 33, while ensuring however, that the forcerequired is sufficiently high to maintain a low likelihood ofinadvertent movement of the lens member 32 during vehicle use.

Referring to FIG. 1b , providing the lens member engagement ribs 82permits the lens member 32 to be held at a selected position in thefront housing member 36 even at relatively high temperatures, such as atemperature that is greater than 85 degrees Celsius, that might reducethe effectiveness of the bonding agent 80 in embodiments where thebonding agent is provided. For greater clarity, it is optionallypossible to omit the bonding agent 80 and to instead provide the lensmember engagement ribs 82 as the primary means for holding the lensmember 32 in place aside from the threaded portions 76 and 78.

The electrical conduits 46 may be bundled in a conduit sleeve 85 and maypass through an electrical conduit aperture 86 in the rear housingmember 38. A seal member 88 may seal between the conduit sleeve 85 andthe electrical conduit aperture 86. The seal member 88 may be anysuitable type of seal member. For example, the seal member 88 may be aheat shrink member that is shrunk by application of heat to form atightly sealed bond with the conduit sleeve 85 and rear housing member38. The seal member 88 may further include a bonding agent, such as anadhesive on its interior wall to assist in bonding to the conduit sleeve85 and rear housing member 38. In addition to providing a seal, the sealmember 88 may further provide strain relief for the rear housing member38, the conduit sleeve 85 and the electrical conduits 46 by providingsome resistance to bending of the sleeve 85 and electrical conduits 46,and by providing some resistance to inadvertent withdrawal of theconduit sleeve 85 from the rear housing member 38.

Referring now to FIGS. 3-5 and the illustrative embodiments depictedtherein, a camera or imaging device or module 110 is adapted for use onor in or at a vehicle and is associated with at least one vision systemof the vehicle. Camera module 110 includes a circuit board or chip orelement 112 (on which an imaging sensor and associated circuitry isestablished), a lens assembly 114 and a housing portion or outer shell116. Housing portion 116 includes a front or lens receiving portion 118and a rear or cable receiving portion 120 that are connected and sealedtogether (such as by laser welding or other suitable sealing means suchas sonic welding or thermal sealing or adhesive sealing or mechanicalsealing or the like) so that the housing portion encompasses or encasesor houses the circuit board 112 and a portion of the lens assembly 114to substantially or entirely encase or encapsulate the circuit board 112and circuitry within the outer shell or housing portion 116. Cameramodule 110 also includes a cable or wire harness 122 that iselectrically connected to the circuitry of circuit board 112 and thatincludes an electrical connector 122 a (such as a multi-pin connector orplug or socket type connector or the like) at or within rear housingportion and an electrical wire or lead 122 b that extends from rearhousing portion 120 and that is electrically connectable to circuitry ora wire harness of the vehicle or the like, so as to provide power andcommunication and control between the vehicle and the camera module. Thewire harness is received through and retained at rear housing portion120 to provide enhanced sealing at the wire harness and housing portionjunction, as discussed below.

As shown in FIG. 3, the lens assembly 114 may be received through andretained and sealed at the lens mounting portion or front housingportion 118 via any suitable retaining and sealing means. Lens assembly114 is secured or attached to circuit board 112 such that the lens opticor optics function to focus and direct and refract an image of the sceneat the field of view of the lens optics onto the imaging sensor. Thelens assembly includes at least one optical element and the lensmounting element is attached to the circuit board so as to provide anoptical path through the at least one optical element to the imagingsensor at the circuit board.

The circuit board or element 112 of camera or imaging device module 110includes a camera or image capture device or sensor for capturing animage of a scene occurring exteriorly or interiorly of a vehicle. Cameramodule 110 may utilize aspects of the cameras or sensors described inU.S. patent application Ser. No. 12/091,359, filed Apr. 24, 2008 andpublished Oct. 1, 2009 as U.S. Publication No. US 2009-0244361; Ser. No.10/534,632, filed May 11, 2005, now U.S. Pat. No. 7,965,336; and/or Ser.No. 11/201,661, filed Aug. 11, 2005 and published Feb. 23, 2006 as U.S.Publication No. US-2006-0038668, which are hereby incorporated herein byreference in their entireties. Optionally, the images captured by theimaging sensor may be communicated to a display or display system whichis operable to display the images to a driver of the vehicle. The cameraor imaging sensor useful with the present invention may comprise animaging array sensor, such as a CMOS sensor or a CCD sensor or the like,such as disclosed in commonly assigned U.S. Pat. Nos. 5,550,677;5,670,935; 5,796,094; 6,097,023 and/or 7,339,149, which are herebyincorporated herein by reference in their entireties.

In the illustrated embodiment, circuit board 112 is secured or attachedor mounted to front housing portion or lens mounting portion 118 to forma circuit board sub-assembly. Circuit board 112 includes circuitry 112a, such as circuitry associated with the imaging sensor. When mounted tothe front housing portion 118, circuit board 112 is received within thecavity or pocket defined by the outer walls of the front housing portion118, with some of the circuitry being located at the opposite side orsurface of the circuit board 112 from the lens receiving structure offront housing portion 118. As shown in FIG. 3, circuitry 112 a includesa connecting element or header 112 b (such as a multi-pin connector orplug or socket type connector or the like) for connecting to a connectoror connecting element 122 a of wire harness 122.

Wire harness 122 includes electrical connector 122 a, such as a plug orsocket type connector or the like, at an end of the wires or cable 122 bfor electrically connecting the wire harness to the connector 112 b ofcircuit board 112. The connector 122 a connects to (such as via plugginginto) the connector 112 b to electrically connect the wire harness tothe circuitry of camera module 110, whereby the connector or connectorsat the opposite end of wire harness 122 may electrically connect to anelectrical connector of the vehicle, so as to provide power and controland signal communication to and from the camera module.

Optionally, the connector 122 a of wire harness 122 may be connected tothe connector 112 b of circuit board 112 prior to or while connecting ormating the housing portions 118, 120 to substantially seal theconnection of the wire harness and module. Such a sealed connection mayprovide a means for retaining the connection without a need for alocking feature at the connectors, and may reduce the strain or providestrain relief for the wire harness at the connection to the cameramodule.

In the illustrated embodiment, the rear housing portion or rear shellportion 120 includes a main wall portion 120 a that defines the cavityof the camera housing or shell when the housing 116 is assembled. Acable receiving portion 120 b extends rearward (or generally away fromthe circuitry 112 and lens assembly 114) from wall portion 120 a and isformed to receive the end of the wire harness 122 therein. The cablereceiving portion 120 b includes a connector receiving portion 120 cthat is formed so as to receive the connector 122 a therein and toretain the connector generally at the rear wall of wall portion 120 aand generally facing the cavity of the camera housing. For example, theconnector receiving portion may be generally rectangular-shaped forreceiving and supporting or retaining a generally rectangular-shapedconnector (although the connector receiving portion may have any othershape that is appropriate for or generally corresponds to the shape ofthe respective connector that is to be received therein). The cablereceiving portion 120 b also includes an outer generally tube portion120 d that is formed to receive the generally cylindrical cable 122 b.For example, the hollow tubular cable receiving portion may be generallycylindrical-shaped for receiving and supporting or retaining a generallycylindrical-shaped cable (although the cable receiving portion maycomprise any other shaped tube or hollow tubular element (such as arectangular or square shaped tube or the like) that is appropriate foror that generally corresponds to the cross-sectional shape of therespective cable that is to be received therein and therethrough). Thus,the rear camera housing portion or shell portion 120 receives cable orwire harness 122 therein and retains connector 122 a at a position wherethe connector 122 a is supported for connection to the circuitryconnector 112 b when the rear housing or shell portion 120 is mated withthe front housing or shell portion 118.

The shape of the cable receiving portion 120 b thus holds the cable orwires 122 b and the cable connector 122 a in a desired or appropriateorientation for connecting the cable connector 122 a to the circuitryconnector or header 112 b. Also, the shape of the cable receivingportion 120 b retains the generally cylindrical cable portion or wires122 b at the desired or appropriate location and orientation relative tocable connector 122 a, thereby reducing strain on the cable andconnector when the cable is moved. Such a configuration also providesenhanced sealing at the cable to housing junction to provide enhancedperformance and enhanced life cycles of the cameras in the field andwhen exposed to harsh environmental conditions.

Optionally, and desirably, the camera module 110 may include a wiresleeve 124 that may be positioned at the connector end of the wireharness to encapsulate or encase the wire harness whereby the wiresleeve may be shrink-wrapped around the end of the wire and a portion ofthe housing portion to encapsulate the end of the wire harness at thehousing portion 120. The wire sleeve and housing portion thussubstantially encase or encapsulate the electrical connection betweenthe wire harness and the circuit board and may retain the connection andmay reduce the strain at the connection of the wire harness to thecircuit board of the camera module.

Thus, the present invention provides for plugging the wire harnessdirectly into a PCB header or connector, which provides the most simpleand direct electrical path. The housing or shell portion of the presentinvention provides a strategically shaped camera housing that receivesthe cable connector and is shaped around the cable connector interfaceand cable, and thus assures that the connector is properly oriented,properly installed and connected and fully seated with the PCB header orconnector when the camera housing or shell is assembled. The housinggeometry also provides off axis cable strain relief when it encloses asmall portion of the cable end (the end of the cylindrical cable at thecable connector) in the form of a short cylindrical-shaped housingportion. The cylindrical housing feature also serves as an appropriatesurface for a thick-walled automotive grade heat shrink tube to bridgeacross to from the cable. The heat shrink serves as both a seal betweenthe camera housing and cable as well as cable strain relief. Such heatshrink tubes are inexpensive and commercially available in a variety ofsizes and grades, and may include a pre-applied adhesive on the interiorsurface for adhering the tube in place at the housing and cable. Whensubjected to temperature extremes, heat shrink has a tendency to shrinkmore when possible, further enhancing the seal and bonds at the cableand camera housing or shell portion. The present invention thus providesa cost advantage over conventional cable exit strategies. Also, thepresent invention provides quality advantages as well.

Optionally, the housing or shell portion may comprise any suitablematerial, such as a plastic or polymeric material, or a metallicmaterial, such as zinc, aluminum or magnesium, or the like. Optionally,the polymeric housing portion and/or the polymeric lens mounting portionmay include conducting or non-conducting material, such as ferrousmaterial or elements (preferably non-conductive ferrous elements),within or on the plastic material, so that the housing portion and/orlens mounting portion may provide shielding properties for EMC and thusenhanced performance of the camera module, such as described above.

The camera module and circuit chip or board and imaging sensor of thepresent invention may be implemented and operated in connection withvarious vehicular vision systems, and/or may be operable utilizing theprinciples of such other vehicular systems, such as a vehicle headlampcontrol system, such as the type disclosed in U.S. Pat. Nos. 5,796,094;6,097,023; 6,320,176; 6,559,435; 6,831,261; 7,004,606 and 7,339,149, andU.S. patent application Ser. No. 11/105,757, filed Apr. 14, 2005, nowU.S. Pat. No. 7,526,103, which are all hereby incorporated herein byreference in their entireties, a rain sensor, such as the typesdisclosed in commonly assigned U.S. Pat. Nos. 6,353,392; 6,313,454;and/or 6,320,176, and/or U.S. patent application Ser. No. 11/201,661,filed Aug. 11, 2005 and published Feb. 23, 2006 as U.S. Publication No.US-2006-0038668, which are hereby incorporated herein by reference intheir entireties, a vehicle vision system, such as a forwardly,sidewardly or rearwardly directed vehicle vision system utilizingprinciples disclosed in U.S. Pat. Nos. 5,550,677; 5,670,935; 5,760,962;5,877,897; 5,949,331; 6,222,447; 6,302,545; 6,396,397; 6,498,620;6,523,964; 6,611,202; 6,201,642; 6,690,268; 6,717,610; 6,757,109;6,802,617; 6,806,452; 6,822,563; 6,891,563 and 6,946,978, and/or in U.S.patent application Ser. No. 10/643,602, filed Aug. 19, 2003, now U.S.Pat. No. 7,859,565, which are all hereby incorporated herein byreference in their entireties, a trailer hitching aid or tow checksystem, such as the type disclosed in U.S. Pat. No. 7,005,974, which ishereby incorporated herein by reference in its entirety, a reverse orsideward imaging system, such as for a lane change assistance system orlane departure warning system or for a blind spot or object detectionsystem, such as imaging or detection systems of the types disclosed inU.S. Pat. Nos. 7,038,577; 5,929,786 and/or 5,786,772, and/or U.S. patentapplication Ser. No. 11/239,980, filed Sep. 30, 2005, now U.S. Pat. No.7,881,496; and/or Ser. No. 11/315,675, filed Dec. 22, 2005, now U.S.Pat. No. 7,720,580, and/or U.S. provisional applications, Ser. No.60/628,709, filed Nov. 17, 2004; Ser. No. 60/614,644, filed Sep. 30,2004; Ser. No. 60/618,686, filed Oct. 14, 2004; Ser. No. 60/638,687,filed Dec. 23, 2004, which are hereby incorporated herein by referencein their entireties, a video device for internal cabin surveillanceand/or video telephone function, such as disclosed in U.S. Pat. Nos.5,760,962; 5,877,897; 6,690,268 and/or 7,370,983, and/or PCT ApplicationNo. PCT/US03/40611, filed Dec. 19, 2003, and published Jul. 15, 2004 asPCT Publication No. WO 2004/058540, and/or U.S. patent application Ser.No. 10/538,724, filed Jun. 13, 2005 and published Mar. 9, 2006 as U.S.Publication No. US-2006-0050018, and/or U.S. provisional applications,Ser. No. 60/630,061, filed Nov. 22, 2004; and Ser. No. 60/667,048, filedMar. 31, 2005, which are hereby incorporated herein by reference intheir entireties, a traffic sign recognition system, a system fordetermining a distance to a leading or trailing vehicle or object, suchas a system utilizing the principles disclosed in U.S. Pat. Nos.6,396,397 and/or 7,123,168, which are hereby incorporated herein byreference in their entireties, and/or the like.

Optionally, the circuit board or chip may include circuitry for theimaging array sensor and or other electronic accessories or features,such as by utilizing compass-on-a-chip or EC driver-on-a-chip technologyand aspects such as described in U.S. Pat. No. 7,255,451 and/or U.S.patent application Ser. No. 11/201,661, filed Aug. 11, 2005, now U.S.Pat. No. 7,480,149; and/or Ser. No. 11/226,628, filed Sep. 14, 2005 andpublished Mar. 23, 2006 as U.S. Publication No. US 2006-0061008, whichare hereby incorporated herein by reference in their entireties. Theimaging array sensor may comprise any suitable sensor, and may utilizevarious imaging sensors or imaging array sensors or cameras or the like,such as a CMOS imaging array sensor, a CCD sensor or other sensors orthe like, such as the types described in U.S. Pat. Nos. 5,550,677;5,670,935; 5,760,962; 5,715,093; 5,877,897; 6,922,292; 6,757,109;6,717,610; 6,590,719; 6,201,642; 6,498,620; 5,796,094; 6,097,023;6,320,176; 6,559,435; 6,831,261; 6,806,452; 6,396,397; 6,822,563;6,946,978; 7,038,577 and 7,004,606; and/or U.S. patent application Ser.No. 11/315,675, filed Dec. 22, 2005, now U.S. Pat. No. 7,720,580; and/orSer. No. 10/534,632, filed May 11, 2005, now U.S. Pat. No. 7,965,336;and/or U.S. provisional applications, Ser. No. 60/845,381, filed Sep.18, 2007; and Ser. No. 60/837,408, filed Aug. 11, 2006, and/or PCTApplication No. PCT/US2003/036177 filed Nov. 14, 2003, and publishedJun. 3, 2004 as PCT Publication No. WO 2004/047421, and/or PCTApplication No. PCT/US2008/076022, filed Sep. 11, 2008 and publishedMar. 19, 2009 as International Publication No. WO 2009/036176, and/orPCT Application No. PCT/US2008/078700, filed Oct. 3, 2008 and publishedApr. 9, 2009 as International Publication No. WO 2009/046268, which areall hereby incorporated herein by reference in their entireties.

Optionally, the camera or imaging device may be positioned at aninterior rearview mirror assembly of the vehicle, and may be located inthe mirror assembly and directed generally forwardly or rearwardly withrespect to the direction of travel of the vehicle for providing anexterior field of view in the forward or rearward direction. Optionally,the camera or imaging device may be directed toward one or morelocations within the vehicle cabin to provide an interior field of view,such as for a cabin monitoring system or the like.

While the above description constitutes a plurality of embodiments ofthe present invention, it will be appreciated that the present inventionis susceptible to further modification and change without departing fromthe fair meaning of the accompanying claims.

1. A method for assembling a vehicular camera for a vehicular visionsystem, said method comprising: providing a front housing member, thefront housing member having a lens receiving portion and a circuit boardattachment portion; disposing a lens assembly at the lens receivingportion, wherein the lens assembly comprises at least one lens;providing a circuit board having a first side and an opposing secondside, wherein an imager is disposed on the first side of the circuitboard and a circuit board connector is disposed on the second side ofthe circuit board; attaching the circuit board at the circuit boardattachment portion of the front housing member; wherein, with thecircuit board attached at the front housing member, the first side ofthe circuit board with the imager disposed thereon is closer to the lensassembly than the second side of the circuit board with the circuitboard connector disposed thereon; providing a rear housing member;providing a conduit that comprises a plurality of electricallyconductive elements terminating at (i) a first connecting end configuredto electrically connect to the circuit board connector disposed on thesecond side of the circuit board and (ii) a second connecting endconfigured to electrically connect to a wire harness of a vehicleequipped with the vehicular camera and the vehicular vision system;securing the conduit relative to the rear housing member to provide atleast 110 N of strain relief in any axis with respect to the conduit;and attaching the front housing member and the rear housing member,wherein, with the front and rear housing members attached, outer wallsof the front and rear housing members enclose the circuit board.
 2. Themethod of claim 1, further comprising, with the circuit board attachedat the front housing member and with the lens assembly disposed at thelens receiving portion of the front housing member, focusing images atan imaging plane of the imager by adjusting the lens assembly relativeto the imager.
 3. The method of claim 2, further comprising, with theimages focused at the imaging plane of the imager, bonding the lensassembly to the front housing member via a bonding agent.
 4. The methodof claim 3, wherein the bonding agent comprises an adhesive.
 5. Themethod of claim 1, wherein the lens receiving portion of the fronthousing member is threaded and wherein at least a portion of the lensassembly is threaded, and wherein disposing the lens assembly at thelens receiving portion comprises threading the lens assembly into thefront housing member.
 6. The method of claim 5, further comprising, withthe circuit board attached at the front housing member and with the lensassembly disposed at the lens receiving portion of the front housingmember, focusing images at an imaging plane of the imager by adjustingthe lens assembly relative to the imager and, with the images focused atthe imaging plane of the imager, bonding the lens assembly to the fronthousing member via a bonding agent, wherein the bonding agent comprisesan adhesive, and wherein the adhesive, when cured, secures threads ofthe lens assembly to threads of the front housing member.
 7. The methodof claim 1, wherein providing the first and second housing memberscomprises forming the first and second housing members of metallicmaterial.
 8. The method of claim 1, wherein attaching the front housingmember and the rear housing member comprises sealing the front and rearhousing members together.
 9. The method of claim 8, wherein the frontand rear housing members are sealed together at least one of (i)adhesively and (ii) mechanically.
 10. The method of claim 1, wherein therear housing member comprises a shaped receiving pocket configured toreceive and retain the first connecting end therein, and wherein thefirst connecting end comprises a shaped connecting end shaped tocorrespond with the shape of the receiving pocket.
 11. The method ofclaim 10, wherein the receiving pocket and the first connecting endcomprise a rectangular shape.
 12. The method of claim 1, wherein theconduit comprises a sleeve that circumscribes the electricallyconductive elements, and wherein the sealing member circumscribes aportion of the sleeve at the rear of the rear housing member.
 13. Themethod of claim 12, further comprising providing a sealing member at thesleeve and the rear housing member, wherein the sealing member retainsand seals the sleeve relative to the rear housing member.
 14. The methodof claim 13, wherein the sealing member comprises a tube thatcircumscribes the conduit and seals around the sleeve at the rearhousing member.
 15. The method of claim 14, wherein the rear housingmember comprises a receiving portion that is shaped to receive an end ofthe sleeve of the conduit, and wherein the tube circumscribes a portionof the receiving portion and seals around the sleeve and the receivingportion.
 16. The method of claim 15, wherein the receiving portioncomprises a cylindrical portion that protrudes outwardly at a rear ofthe rear housing member away from the front housing member.
 17. Themethod of claim 1, wherein the circuit board is attached at the circuitboard attachment portion of the front housing member by a plurality offasteners.
 18. The method of claim 1, wherein the circuit boardattachment portion of the front housing member has a generallyrectangular shape and wherein the lens receiving portion is coextensivewith the circuit board attachment portion and extends outward therefromwith a cylindrical shape.
 19. The method of claim 18, wherein at least aportion of the lens assembly is cylindrically shaped, and wherein thelens receiving portion of the front housing member comprises an aperturedimensioned to receive the at least a portion of the lens assembly thatis cylindrically shaped.
 20. The method of claim 19, wherein the lensreceiving portion of the front housing member is threaded and whereinthe at least a portion of the lens assembly that is cylindrically shapedis threaded, and wherein disposing the lens assembly at the lensreceiving portion comprises threading the lens assembly into the fronthousing member.
 21. The method of claim 1, wherein the vehicular cameracomprises a rearview camera for a vehicle and wherein the imagercomprises a CMOS imaging sensor.
 22. The method of claim 1, furthercomprising passing the first connecting end of the electricallyconductive elements through an aperture of the rear housing member forelectrically connecting the first connecting end of the electricallyconductive elements to the circuit board connector disposed on thesecond side of the circuit board.
 23. A method for assembling avehicular rearview camera for a vehicular vision system, said methodcomprising: providing a front housing member comprising a metallicmaterial, the front housing member having a lens receiving portion and acircuit board attachment portion; disposing a lens assembly at the lensreceiving portion, wherein the lens assembly comprises at least onelens; providing a circuit board having a first side and an opposingsecond side, wherein an imager is disposed on the first side of thecircuit board and a circuit board connector is disposed on the secondside of the circuit board, and wherein the imager comprises a CMOSimaging sensor; attaching the circuit board at the circuit boardattachment portion of the front housing member; wherein, with thecircuit board attached at the front housing member, the first side ofthe circuit board with the imager disposed thereon is closer to the lensassembly than the second side of the circuit board with the circuitboard connector disposed thereon; providing a rear housing membercomprising a metallic material; providing a conduit that comprises aplurality of electrically conductive elements terminating at (i) a firstconnecting end configured to electrically connect to the circuit boardconnector disposed on the second side of the circuit board and (ii) asecond connecting end configured to electrically connect to a wireharness of a vehicle equipped with the vehicular rearview camera and thevehicular vision system; passing the first connecting end of theelectrically conductive elements through an aperture of the rear housingmember; electrically connecting the first connecting end of theelectrically conductive elements to the circuit board connector disposedon the second side of the circuit board; securing the conduit relativeto the rear housing member to provide at least 110 N of strain relief inany axis with respect to the conduit; and attaching the front housingmember and the rear housing member, wherein, with the front and rearhousing members attached, outer walls of the front and rear housingmembers enclose the circuit board.
 24. The method of claim 23, furthercomprising, with the circuit board attached at the front housing memberand with the lens assembly disposed at the lens receiving portion of thefront housing member, focusing images at an imaging plane of the imagerby adjusting the lens assembly relative to the imager, and, with theimages focused at the imaging plane of the imager, bonding the lensassembly to the front housing member via a bonding agent.
 25. The methodof claim 23, wherein the rear housing member comprises a shapedreceiving pocket configured to receive and retain the first connectingend therein, and wherein the first connecting end comprises a shapedconnecting end shaped to correspond with the shape of the receivingpocket.
 26. The method of claim 23, further comprising providing asealing member at the conduit and the rear housing member, wherein thesealing member secures and seals a sleeve of the conduit relative to therear housing member, and wherein the sealing member comprises a tubethat circumscribes the sleeve and seals around the sleeve at the rearhousing member, and wherein the rear housing member comprises areceiving portion that is shaped to receive an end of the sleeve, andwherein the tube circumscribes a portion of the receiving portion andseals around the sleeve and the receiving portion.
 27. The method ofclaim 23, wherein the circuit board is attached at the circuit boardattachment portion of the front housing member by a plurality offasteners.
 28. A method for assembling a vehicular rearview camera for avehicular vision system, said method comprising: providing a fronthousing member, the front housing member having a lens receiving portionand a circuit board attachment portion, wherein the circuit boardattachment portion of the front housing member has a generallyrectangular shape and wherein the lens receiving portion is coextensivewith the circuit board attachment portion and extends outward therefromwith a cylindrical shape; disposing a lens assembly at the lensreceiving portion, wherein the lens assembly comprises at least onelens, wherein at least a portion of the lens assembly is cylindricallyshaped, and wherein the lens receiving portion of the front housingmember comprises an aperture dimensioned to receive the at least aportion of the lens assembly that is cylindrically shaped; providing acircuit board having a first side and an opposing second side, whereinan imager is disposed on the first side of the circuit board and acircuit board connector is disposed on the second side of the circuitboard, and wherein the imager comprises a CMOS imaging sensor; attachingthe circuit board at the circuit board attachment portion of the fronthousing member; wherein, with the circuit board attached at the fronthousing member, the first side of the circuit board with the imagerdisposed thereon is closer to the lens assembly than the second side ofthe circuit board with the circuit board connector disposed thereon;providing a rear housing member; providing a conduit that comprises aplurality of electrically conductive elements terminating at (i) a firstconnecting end configured to electrically connect to the circuit boardconnector disposed on the second side of the circuit board and (ii) asecond connecting end configured to electrically connect to a wireharness of a vehicle equipped with the vehicular rearview camera and thevehicular vision system; securing the conduit relative to the rearhousing member to provide at least 110 N of strain relief in any axiswith respect to the conduit; and attaching the front housing member andthe rear housing member, wherein, with the front and rear housingmembers attached, outer walls of the front and rear housing membersenclose the circuit board, and wherein the front and rear housingmembers are secured together at least one of (i) adhesively and (ii)mechanically.
 29. The method of claim 28, wherein the lens receivingportion of the front housing member is threaded and wherein at least aportion of the lens assembly is threaded, and wherein disposing the lensassembly at the lens receiving portion comprises threading the at leasta portion of the lens assembly that is cylindrically shaped into theaperture of the lens receiving portion of the front housing member. 30.The method of claim 28, wherein providing the first and second housingmembers comprises forming the first and second housing members ofmetallic material.
 31. The method of claim 28, wherein the rear housingmember comprises a shaped receiving pocket configured to receive andretain the first connecting end therein, and wherein the firstconnecting end comprises a shaped connecting end shaped to correspondwith the shape of the receiving pocket.
 32. The method of claim 28,further comprising providing a sealing member at the conduit and therear housing member, wherein the sealing member secures and seals theconduit relative to the rear housing member, wherein the sealing membercomprises a tube that circumscribes the conduit and seals around theconduit at the rear housing member, and wherein the rear housing membercomprises a receiving portion that is shaped to receive an end of theconduit, and wherein the tube circumscribes a portion of the receivingportion and seals around the conduit and the receiving portion.
 33. Themethod of claim 32, wherein the conduit comprises a sleeve thatcircumscribes the electrically conductive elements, and wherein thesealing member circumscribes a portion of the sleeve at the rear of therear housing member.
 34. The method of claim 28, further comprisingpassing the first connecting end of the conduit through an aperture ofthe rear housing member for electrically connecting the first connectingend of the conduit to the circuit board connector disposed on the secondside of the circuit board.
 35. The method of claim 28, wherein attachingthe front housing member and the rear housing member comprises sealingthe front housing member relative to the rear housing member.